BE_Info_1_2010_engl1.pdf

Magazine for Customers and

Employees

1/2010

Edelstahl

POWERD I M E N S I O N S

for new

EDELSTAHL Info 1/20102

Top-class heavy metal performanceInauguration of the new 80/100 MN forging press4

Contents

l The Company

4 Is the worst behind us?We hope so!

5 Top-class heavy metal performanceInauguration of the new 80/100 MN forging press, with guests from all over the world

7 Employees and friends celebrate the new 80/100 MN forging pressThousands of visitors fl ock to the Buderus Edelstahl works

9 Navaratna – nine precious stones for celestial protectionLaying the foundation stone of the 80/100 MN open-die forging press

10 Miniature press:The big press’s little sister

10 The Buderus Edelstahl image fi lm

11 UNESCO presents Rimkus project in SeoulForging laboratory on the move

l Tool Steel

12 Refl ective steel and top contactsEuroMold 2009

l Engineering alloys

14 Mega-bolts for gigantic cranesSpecial engineering alloys from Bude-rus Edelstahl

Mega-bolts for gigantic cranesSpecial engineering alloys from Buderus Edelstahl14

Forging laboratory on the move

The Buderus Edelstahl chain forgeBetween chains and ingot moulds

11

16

Editorial

Dear Readers,

We have an exciting fi rst quarter behind us. Four hundred business partners from all over the world together with guests from the fi elds of business and politics celebrated with us the offi cial inauguration of the new 80/100 MN open-die forging press, as did four thousand employees and friends. The heavy-metal performance was a big hit, as was the fully functional 1:20 scale model of the press. This issue reports in detail on this outstanding event. You can also read the nice story about laying the foundation stone with nine precious stones from India.

Our new image fi lm with a brief and intriguing journey through time from the year 1731 to the present day is now available on DVD. There is information on it in this newsletter.

Sustainability is the issue addressed in the article on the Hesse Environment Alliance, and on the “100 companies for climate protection” initiative. Buderus Edelstahl is represented in both – for good reason.

There is naturally a report on the most recent EuroMold trade fair. Buderus Edelstahl entranced international exhibition visitors with its refl ective allure in December 2009.

We also report on the largest cranes in the world, with bolts made from our special engineering alloys; and we have another remarkable profi le for you – the Buderus Edelstahl chain forge.

We hope you enjoy reading this newsletter, and wish you a traditional “Glück auf!”

Your Management Team

Karl-Peter JohannJens Mohr

l Employees / News

16 The Buderus Edelstahl chain forgeBetween chains and ingot moulds

18 Buderus Edelstahl:Member of the Hesse Environment AllianceCommitted to climate and environ-ment protection

19 Long service awards

19 Deaths

19 Editorial information

EDELSTAHL Info 1/2010 3

Refl ective steel and top contactsEuroMold 200912


The operating result for the 2009/10 finan-cial year ending on 31 March 2010 was down, as is to be expected in the circum-stances, but nevertheless positive, thanks to internal efforts. Steel mill production hit a historical low in April 2009, running at only about 25 % of the usual utilisation level, but thereafter production picked up, modestly at first, then increasing progres-sively. As in the case of Buderus Edelstahl, the main priority for all companies in 2009 was reducing work in progress and inven-tories in order to release capital. The impact of such de-stocking was and will continue to be greater on companies higher up the value-added chain. As a steelmaker, Buderus Edelstahl is very high up the sup-ply chain, which accounts for the dispro-portionate decline in the level of activity in 2009.

Just as the decline was disproportion-ately great compared to overall demand, so we are now experiencing a boom in orders in all companies of the Buderus Edelstahl Group. By resorting to short-time working, we have succeeded in retaining most of the qualified employees necessary for produc-tion, although the past year has undeniably left its mark on the workforce, since the bleak outlook meant that some employees could not be retained.

Like our customers, we are still regarding the current recovery phase with healthy scepticism, since it is by no means certain that the level of activity will be sustained. Another factor is the effect described above whereby Buderus Edelstahl is by the

nature of its products more exposed to volatility in the economy than end-product manufacturers. The upturn could therefore be short-lived.

We nevertheless welcome the significant recovery in the level of activity, which the company’s workforce has responded to with alacrity, even though there have been and may still be numerous alterations to shift patterns. Management would like to take this opportunity to thank the work-force for their flexibility and loyalty.

In this context, the worst is surely be-hind us as regards the employment situa-tion. The aim is now to meet the challenges of boosting production, whilst remaining sufficiently flexible to be able to respond rapidly to any downturn that may yet oc-cur.

80/100 MN open-die forging pressCompletion of this project has been both difficult and rewarding. The construction phase with its huge earth movements and

associated dirt, the cold of two long, hard winters on the exposed, draughty construc-tion sites and halls, and the obstacles in-volved in transporting the heavy compo-nents. Once a casting weighing 250 tonnes almost got stuck in the centre of Oberlemp, a small town in the Wetzlar district, and once the Midland Canal was threatening to freeze over, and the 350 tonne foundation wailing was ice-bound for days. But the press finally started up right on schedule, after two years’ construction. We would like to take this opportunity of congratu-lating and thanking all those involved for their achievement.

Those who attended the press inaugura-tion ceremony in person will doubtless long remember this event. The inauguration comprised an open day for customers, with presentations addressing matters of inter-est to the audience. But the inauguration of the press itself was doubtless much more impressive, accompanied as it was by an outstanding forging performance with magnificent sound and light effects. The highly emotional mix of light, classical music, techno and hard rock, combined with the direct heat emitted by a glowing steel ingot, and the deceptive ease with which the new press forges large ingots, is something the audience will long remem-ber.

In organising this event, we were guided by the principle of “let your good works shine”. Despite the constrained financial situation, this event just had to be cele-brated. And our customers’ response has justified the decision, as some promising transactions were initiated both on the day and thereafter.

So the question posed above can cer-tainly be answered in the affirmative, espe-cially in the short term, once we look be-yond the day-to-day shortcomings. But there will undoubtedly be further chal-lenges ahead, which we will also meet just like those we faced last year.

Is the worst behind us?

We hope so!That describes the situation in a nutshell. But the reply to the question can also be very much more nuanced. The issues that concern us all can rarely be answered with a simple affirmative. So what answers do we have to the employment situation? What answers are we giving with our new forging press? What are the changed future scenarios like, and how should we deal with them?

The Company


Karl-Peter Johann, Technical Director of Buderus Edelstahl, gave an interesting overview of the whole project

Jens Mohr, Commercial Director of Buderus Edelstahl, giving his welcoming address

The Company

Inauguration of the new 80/100 MN forging press, with guests from all over the world

Top-class heavy metal performance400 guests from industry and politics came together on 18 March 2010 to celebrate the impressive launch of the new open-die forging press at Buderus Edelstahl. This major event was attended by customers and international sales partners, suppliers, all the directors of Böhler-Uddeholm AG, and political representatives. They enjoyed a celebration of superlatives.

Buderus Edelstahl had really rolled out the blue carpet. The inaugural celebrations un-der the motto “Power for New Dimensions” started in the elegantly decorated marquee with a presentation of the new Buderus Edelstahl image film. Commercial Director Jens Mohr greeted the guests, and thanked the local government representatives pres-ent, including the Environment Minister of the state of Hesse, Silke Lautenschläger, District President Dr Lars Wittek, and the Mayor of Wetzlar, Wolfram Dette, for their effective cooperation during the prepara-tion and construction phase of the new open-die forging press project.

The facilitator Dirk Daniels, whose agen-cy organised the event in close cooperation with Anne Kuhlmann, Assistant to Buderus Edelstahl management, then led the guests to their tiered seats in the new production hall. The main attraction was still concealed behind a huge curtain, which gave an ini-tial clue to the size of the new open-die forging press.

Buderus Edelstahl Technical Director Karl-Peter Johann gave an interesting overview of the whole project, which had started two years previously. He observed that a total of more than 200,000 tonnes of material had been moved since


the first spade was dug, making a light-hearted comparison with Cologne Cathe-dral, which took a mere 120,000 tonnes of material to build its walls and towers. After the necessary preparatory work, including expanding the substation in the nearby town of Asslar, the centre of this major construction project was at first just a gi-gantic hole 40 metres long, 30 metres wide and up to 17 metres deep – the construc-tion pit for the new four-column under-floor press together with the hydraulics pit. The complete infrastructure was adapted to the new press, which is the fastest in its weight class.

The logistics system was also converted from rail to flexible transport systems cap-able of handling ingots of up to 180 tonnes. The furnace capacity was expanded with new forging furnaces, and all the periph-eral facilities such as the annealing plant and hardening plant were upgraded ac-cordingly. A forge crane and a new mani-pulator complete the imposing gigantic press. With a lifting capacity of 250 tonne metres, it has more than twice the capacity of the largest existing manipulator at Bud-erus Edelstahl. “This investment programme puts us in a good position for the future in terms of quality, technology, and competi-tion”, said Karl-Peter Johann in conclusion, as he handed over to the Environment Minister of the State of Hesse, Silke Lau-ten schläger.

Member of the Hesse Environment AllianceIn her opening address, Ms Lautenschläger officially confirmed Buderus Edelstahl’s admission to the Hesse Environment Alli-ance. The Minister had been impressed by the company’s commitment to greater en-ergy efficiency and reduced environmental impact. Buderus Edelstahl was exemplary for other companies that did not yet have such a focus on the issue of energy effi-ciency. The company was also creating new jobs, and its investment decision consti-tuted a commitment to the location. Ms Lautenschläger concluded, “Economics and ecology need not be mutually exclusive”, wished the assembled audience the tradi-tional miners’ greeting of “Glück auf!”, and

opened the new forging press with three hammer blows on the anvil.

Power for new dimensionsHardly had the last hammer blow faded away when a unique forging performance began. The forging artist Andreas Rimkus and two muscular gentlemen presented an impressive choreography involving the craft of forging, pyrotechnics, and torch juggling, framed by dry-ice fog, fire foun-tains and Carl Orff’s “Carmina Burana”. This was followed by a large glowing steel ingot suspended from a crane hook proceeding between two banks of seated spectators towards the still concealed press. The ex-citement mounted, the curtain fell with a loud bang, and guests saw a brilliant sight – the massive new forging press dominat-ing the space.

After this prelude the event proceeded in an equally breathtaking way. AC/DC’s “Hell’s Bells” followed the classical piece, with the new manipulator demonstrating the full range of its flexibility, dancing to the rhythm of the hard rock. Accompanied by Doldinger’s music for the film “The Boat”, the steel ingot finally reached the forging press, to have its imposing two me-tre bulk flattened within a few moments, to enthusiastic applause by the audience. The new 80/100 MN open-die forging press had officially started work.

Emotion and information – an all-round successWith its new press and the company’s out-standing materials know-how, Buderus Edelstahl has immense “power for new di-

Environment Minister Silke Lautenschläger officially confirmed Buderus Edelstahl’s participation in the Hesse Environment Alliance

Forging artist Andreas Rimkus (right) provided an impressive choreography of the craft of forging

The new manipulator gave a dancing performance to demonstrate the extent of its flexibility

The steel ingot was swaged flat within a few moments

The public is totally absorbed by the presentation

The elegantly decked marquee was full of guests

The Company

After the opening address by Wolfram Dette, Mayor of the City of Wetzlar, and by Karl-Peter Johann, the crowds of visitors could hardly wait to see the new forging press in action. The organiser Dirk Daniels had to apply all his communication skills to direct the run on the total of six press pre-

sentations in an orderly fashion. The guests were thrilled by what they saw. They shared the experience of the guests from business and politics who had witnessed the official inauguration two days previously under the motto “Power for new dimensions”.


The new forging press in actionKarl-Peter Johann, Technical Director, during the opening address

Welcoming speech by the Mayor of the city of Wetzlar, Wolfram Dette

Around 4,500 visitors, employees and friends of the company came to Buderus Edelstahl on 20 March to admire the new 80/100 MN open-die forging press. The visitors packed into the works tour, renewed old workplace acquaintances, and made good use of the many attractions Buderus Edelstahl had organised for this special day.

Thousands of visitors flock to the Buderus Edelstahl works premises

Employees and friends celebrate the new 80/100 MN forging press

mensions” – all the guests agreed on that. Dr Claus Raidl, Chairman of the Manage-ment Board of Böhler-Uddeholm AG, em-phasised, “For our company, this is the larg-est forging press in the world – the right

decision at the right location. Buderus Edel-stahl is a fantastic brand, Germany is a fan-tastic market, we have well trained people here.” Buderus Edelstahl has invested € 100 million in the entire project launched this

day, a day that will be long remembered. So impressive that the local press observed next morning, “Rarely has such a produc-tion plant colossus been greeted in such a stylish and spectacular manner.”

Works tours of a special kindThe team associated with the 80/100 MN open-die forging press

The Company


Steel structures for the new workshop and a fully enclosed access road were con-structed in two phases to meet the high noise reduction requirements. A carefully designed ventilation system ensures the health and safety of the employees inside the new workshop.

Visitors inspected the 250 tonne and 300 tonne forging furnaces with interest, and the new MAFI transport systems that are replacing the old rail transport system, and can handle ingots weighing up to 180 tonnes.

“Absolutely gigantic!”, was one visitor’s summary of what he had seen. “A magnifi-cent celebration of the new press. A day none of us will soon forget.”

Impressive all roundMany former employees were pretty im-pressed when they saw the new open-die forging press, the brand-new sparkling workshop, and the associated peripheral area on the site. This is where construction of the press started in September 2009, with installation of the equipment in the hydraulics pit.

The new press gives Buderus Edelstahl the capacity to forge large-scale com-ponents with diameters of up to almost 4 metres. The compression force amounts to 8,000 tonnes; in the slower swaging mode the press even achieves a compres-sion force of 10,000 tonnes.

The new 250 tm manipulator acquired for the 80/100 MN press, was also widely admired. With good reason – it has more than twice the capability of Buderus Edel-stahl’s second largest manipulator.

Music, fun and gamesIn two large marquees, the Original Münch-holzhäuser group entertained the crowds with excellent brass band music, there was food and drink, and a children’s circus for young visitors. There were also games of skill on offer, such as the soccer Olympics, offering some worthwhile prizes. Of course Andreas Rimkus’ forging laboratory was on site, and two other highlights were in great demand – the miniature press made in the Buderus Edelstahl training workshop, on which the trainees struck commemorative medals during the event, and the five min-iature railways to carry visitors on half-hourly works tours.

Karl-Peter Johann, Josef Prexler, who worked in the forge for 43 years, and Arno Ferber, General Forging Foreman (from left to right)

1:20 scale model of the new 80/100 MN – a miniature press built in our training workshop

Forging Press Operator Harald Müller operated the press during both events

The Children’s Circus team for young guests

Lufino the clown models fantastic balloon figures

A bus and miniature railway station set up specially for this day

The crowds of visitors could hardly wait to see the new forging press in action

Thousands of people poured into the Buderus Edelstahl works

The Company

All the seats were taken for all six press presentations


Laying the foundation stone of the 80/100 MN open-die forging press

Navaratna – nine precious stones for celestial protection

The Company

Ralf Rech, Tobias Besser, Nicol Müller, Diana Schäfer, Wolfgang Wichert, Karl-Peter Johann, Paul Schmitz and Jens Mohr (from left to right) at the laying of the foundation stone

The Vedic talisman found its place at the important interface of the press and ma-nipulator foundation in a horizontal hole drilled 150 mm deep, with a diameter of 100 mm. Together with some employees,

Karl-Peter Johann and Jens Mohr em-bedded the precious stones and precious metals in the foundation encased in a spe-cial-steel cylinder on 9 November 2009.

The precious stones symbolise seven planets, and the ascendant and descendant lunar nodes. Heavenly bodies have a direct influence on all aspects of our life in the Vedic faith. Certain stones and metals are associated with corresponding heavenly bodies and effects on their environment. Whenever someone builds a house or an industrial structure, you embed the Nava (nine) Ratna (precious stones) in the foun-dation.

This combination of stones goes back to the “Brihat Jatak”, as it is called in the San-skrit language of the Brahmans, one of the most important dissertations on Vedic as-trology in the old scriptures. It sets out the association of the stones with the particu-

lar planets (see box). The selected stones must be of exquisite quality, and flawless. Embedded in the foundation of a building, they are supposed to absorb the energy of the heavenly bodies, protecting their envi-ronment against negative influences. Many people also wear the nine precious stones as a ring or protective amulet.

The five small precious-metal discs that rest in the foundations together with the precious stones are associated in the Indian philosophy with five elements: earth water, air, fire, and ether. In the foundation, all five together symbolise wealth and success. “We are delighted with this talisman, and thank the Laxman family again most sin-cerely”, says Jens Mohr. “With such good protection we can all go forward together into a promising future.”

The stones of the Navaratnal Pure ruby for the Sunl Pearl for the Moonl Red coral for Marsl Emerald for Mercuryl Yellow sapphire for Jupiterl Diamond for Venusl Blue sapphire for Saturnl Essonite for the ascendant

lunar nodesl Cat’s eye for the descendant

lunar nodes

The Laxman family, the Indian partner of Buderus Edelstahl, presented Buderus Edelstahl management with a truly special talisman. Nine pure little precious stones and five precious metals have been protecting the new open-die forging press project since the foundation stone was laid on 9 November 2009.

Jens Mohr embeds the precious stones and precious metals encased in a special-steel cylinder into the foundation

The five small precious-metal discs that are incorporated in the foundations together with the precious stones


The Company

The training workshop at Buderus Edel-stahl created a “small” masterpiece with the miniature version of the new 80/100 MN press. The 1:20 scale model was received with enthusiasm by customers and friends of the company during the offi cial celebrations for the new press.

the model press, and gave the order to the training workshop at the end of January 2010. Converting the size and complexity of the 80/100 MN press to a viable func-tional model required total commitment. The March deadline was tight, and costs had to be contained within reasonable lim-its. No problem for the dedicated team. The trainees themselves did the work to pro-duce the individual components and to conduct the stamping tests. The trainers Otfried Bremer and Steffen Dornbusch co-ordinated project planning, engineering design, welding, assembly, surface fi nishing and commissioning. Order placement and materials procurement were handled by the Training Supervisor Alfred Lepper. Gerhard von Mohr and his people managed the turning work, and adaptation to the pro ject. The group associated with Mathias Schaub carried out milling work and assembly, and Oliver Tröller was responsible for procuring the hydraulic components. The miniature press was commissioned less than two months later, on 16 March 2010.

The model illustrates the functioning of the 80/100 MN open-die forging press, and can be fi tted with various stamping dies. It functions on the same principle as the large press; a small hydraulic unit enables the upward and downward movement of the crosshead, using a control valve in the lower part of the model press. At a pressure of 450 bar (45 MPa), forces of up to 400 kN can be applied. “Our model press will fre-quently be used in future presentations and events for our company and our prod-ucts”, says Karl-Heinz Schäfer, Head of the Training Workshop. “We have numerous options with modifi ed stamping dies.” We look forward to seeing what the miniature press will create in future.

Miniature press:The big press’s little sister

The Buderus Edelstahl image fi lmThe guests at the inauguration ceremony were shown the new Buderus Edelstahl image fi lm. Images from the past, innovative materials and production facilities, cutting-edge products in various industries – a brief and exciting trip from the year 1731 through to the present and into the future of a company that is now the world market leader with many of its products. The image fi lm will be available on the Buderus Edelstahl website from summer 2010. The DVD is also available from: Buderus Edelstahl GmbH, Department GF/K-A, Tel.: +49 (0) 6441/374-2875, Fax: +49 (0) 6441/374-2301, e-mail: [email protected]

The miniature press is not only pleasing to look at, it can also stamp items such as commemorative medals from copper, measuring 30 x 2 mm. They were in great demand on 18 and 20 March.

Karl-Peter Johann, Technical Director of Buderus Edelstahl, had the idea of building

The guests at the inauguration ceremony were shown the new Buderus Edelstahl image fi lm. Images from the

cutting-edge products in various industries – a brief and exciting trip from the year 1731 through to the

the world market leader with many of its products. The image fi lm will be available on the Buderus Edelstahl website from summer 2010. The DVD is also available from:

Tel.: +49 (0) 6441/374-2875,

e-mail: [email protected]

Buderus Edelstahl GmbHBuderusstraße 25D-35576 Wetzlar

Tel.: +49 (0 ) 64 41 / 374 - 0Fax: +49 (0 ) 64 41 / 374 - 2882

E-Mail: [email protected]

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Inhalt:

Imagefilm Buderus Edelstahl

Corporate Video Buderus Edelstahl

Event "Kraft für neue Dimensionen" 18.03.2010 "Power for new Dimensions"

KRAFT für neueD I M E N S I O N E N

The team associated with the miniature press: Gerhard von Mohr, Otfried Bremer, Matthias Schaub, Oliver Tröller, Steffen Dornbusch, Alfred Lepper (from left to right)


Forging laboratory on the move

UNESCO presents Rimkus project in Seoul

The UNESCO World Conference was held from 25 to 28 May 2010 in Seoul, Korea. The special dossier of the German UNESCO Commission is intended to refl ect “good practice from Germany in the fi eld of arts education”. The mobile forging laboratory item will appear as a model project in the section entitled “Learning Spaces and Part-nerships, Target Groups”.

Because forging is part of our culture, as the German UNESCO Commission and oth-ers confi rm. “The UNESCO World Confer-ence in Korea is a good platform for a very good project, comments Jens Mohr, Com-mercial Director of Buderus Edelstahl. “We have been pleased to work with Andreas Rimkus for many years. He recently forged his latest work of art entitled “Twisted world” in our works. We are pleased that

Rimkus’ concept art fi nds international recognition.”

On the moveThe mobile forging laboratory, a travelling sculpture in the form of an anvil, takes chil-dren and young people on a journey through the craft of forging, and gives them the op-portunity to try their hand at this ancient skill. Equipped with four hearths and eight anvils, one of which can also be operated by children in a wheelchair, and equipped with all the most important forging tools, this hands-on exhibit has been fascinating forg-ing fans young and old since its fi rst major appearance at the Idea Park 2008 in Stutt-gart. Its latest appearance was in Wetzlar again, from 18 to 20 March 2010 at the fes-tive inauguration of the new 80/100 MN

“Arts and education in and by Germany” is the working title of a special dossier to be presented by the German UNESCO Commission as the German contribution to the UNESCO World Conference on Arts Education, including Andreas Rimkus’ mobile forging laboratory as a representative project.

open-die forging press, as one of several key attractions.

Forging for realMore than 8,000 children have tried their hand at forging in the mobile laboratory in less than two years. In an experience trans-cending everyday schoolwork, they dis-cover how to model and shape this hard material with their own hands, using their own strength and imagination to create objects. A further attraction of the mobile forging laboratory for young visitors is the interactive information terminal. Last year the visitors were not just from Germany; in July 2009 the mobile forge visited the Zui-dermuseum in Holland. Then it went to the IdeenExpo in Hanover, then to the Ems-landschau regional show, and from there to Hamlin and to Aachen. This year the fasci-nating exhibit is scheduled to visit Mein-erz hagen, Papenburg, Springe, Dillenburg and Hagen. Further details on these events can be accessed on the website: www.ideenkunst.de/amboss/reise.htm.

The forging laboratory presence at the inauguration of the new 80/100 MN open-die forging press

The Company


Anyone who has attended major trade fairs knows that you just walk past many stands, whereas others exert an irresistible attrac-tion. A mirror made of steel caught the eye of international visitors to Frankfurt in early December 2009. The steel plate weigh ing almost 100 kilos and measuring 440 x 35 x 800 mm was made of 2738 mod. Thruhard Supreme®, and enthralled every-one who looked at it, with its polished mirror surface. This exhibit in cooperation with Kiefer GmbH enabled Buderus Edel-stahl to effectively convey a good example of top-class mould surface finishing. The largest exhibit on the stand was a pre-ma-

chined mould for a bumper die, likewise made of Thruhard Supreme®. This high-quality plastic mould steel from Buderus Edelstahl is in demand throughout the world. For example the automobile indus-try uses large moulds made of Thruhard Supreme® to manufacture vehicle compo-nents such as bumpers, because this ex-cellent material has a distinctly uniform microstructure achieved by a specially adapted alloying and heat-treatment con-cept. This steel is highly prized internation-ally for its excellent mechanical properties, good polishability, and uniform etch-grain-ability.

EuroMold 2009

Reflective steel and top contactsThe EuroMold trade fair in Frankfurt am Main has always been an important event for Buderus Edelstahl. It is the leading international world fair for mouldmaking and tooling, design and application development. The 16th EuroMold exhibition was held from 2 to 5 December 2009. The Buderus Edelstahl stand covered 140 square metres, and attracted a large number of visitors. One reason was brilliant exhibits made of Thruhard Supreme®

Tool Steel

Buderus Edelstahl employees and global sales partners

Ulli Keiner, Tool Steel Sales Far East, in front of the mirror made of Thruhard Supreme®


tential it generates.” Buderus Edelstahl has made good use of the crisis period. New production facilities, faster throughput times, high flexibility with excellent quali-ty – the messages were clearly understood and well received. The conversations at EuroMold will now be turned into action. We can already say that Buderus Edelstahl’s participation in this important internatio-nal trade fair was again a complete suc-cess.

Tool Steel

Opportunities from the crisisCustomers from all over the world were greeted on the exhibition stand by Buderus Edelstahl employees and sales partners from around the world, and by employees from the French company Deville Rectifi-cation; two major issues featured promi-nently in their discussions. One was the expanded production facilities of Buderus Edelstahl with the new 80/100 MN open-die forging press officially commissioned in March 2010, with its state-of-the-art peri pherals, and resultant advantages for Buderus Edelstahl customers. The second hot topic was the current economic situa-tion. The general tenor was cautious opti-mism. Most visitors believed the market was picking up again. This was also sug-gested by the exhibition attendance fig-ures: the 16th EuroMold attracted more than 56,000 visitors from 86 countries, de-spite the still very difficult economic envi-ronment. Although the total attendance at the exhibition was somewhat down on last year, the proportion of foreign visitors was slightly higher than in 2008.

Good contacts in an important core businessThere was also an increase in the propor-tion of the largest group of visitors from the automobile industry, 17 % up on 2008; their specialist interest is in mould and tool making, one of Buderus Edelstahl’s core

businesses. “All our key customers were there”, says Jens Mohr, Commercial Direc-tor of Buderus Edelstahl, “the quality of contacts with existing and potential cus-tomers was again very good.” He adds, “We regularly encounter a high level of in-terest with our innovative steel concepts. And the successful implementation of our TOPFORGE project makes us even stronger than before in our core markets. The con-versations therefore related to the new po-

The Buderus Edelstahl exhibition stand attracted numerous visitors to its 140 square metres of floor space Large exhibit – pre-machined mould for a bumper die

Josef Puchner, Toolmaking / Vehicle Components and Systems Manager, Marcus Hoermannskirchner, Tool-making, present a gift to Peter Vetter, Tool Steel Quality Planning Manager, Erwin Kreisel, Field Service and Oliver Schaub, Domestic Tool Steel Sales, to express their appreciation of a two-day tool steel seminar held at the BMW facility in Landshut


The company is headquartered in Ehingen on the Danube, and develops and produces numerous models of mobile crane with telescopic and lattice jibs on mobile and crawler platforms for the most diverse pur-poses all around the world. Liebherr has the most modern crane factory in the world, capable of producing more than 1,500 mo-bile and crawler cranes per year. That is at least six a day. That sounds a lot, and it is – but the demand for mobile and crawler cranes has grown steadily in recent years, and the boom is continuing. The largest crawler crane internationally is currently

being built in Ehingen; it is of conventional design, with a lifting capacity of 3,000 tonnes. The tallest lattice mast cranes on a crawler chassis were being built here as long ago as 1994, with a lifting capacity of 1,200 tonnes, and a lifting height of 226 metres. This specialist crane builder was formed in 1969 as a subsidiary of the then sole proprietorship Hans Liebherr; its pro-duction facility now employs a workforce of 2,700 on a site extending to 820,000 m2, of which 184,000 m2 is dedicated to pro-duction.

Special engineering alloys from Buderus Edelstahl

Mega-bolts for gigantic cranesFor many years Buderus Edelstahl has been working closely with the crane maker Liebherr-Werk Ehingen GmbH. This market leader procures special engineering alloys from Wetzlar for its mobile and crawler cranes; the steel is used to make the mighty bolts for Liebherr cranes – the largest in the world.

Engineering Alloys

Liebherr cranes on major construction sites throughout the world


Engineering Alloys

Special engineering alloys for the most demanding applicationsLiebherr uses strong partners like Buderus Edelstahl to meet the exacting demands made on its mobile cranes. In addition to constant innovation in developing hydrau-lic, electrical and electronic drive and con-trol systems, it is principally the materials that have to satisfy the most exacting de-mands.

Buderus Edelstahl supplies Liebherr with special engineering alloys in diameters ranging from around 220 to 540 mm for machine elements that are essential for the machine to operate – the bolts. The core components of any crane are linked by flexible shafts weighing tonnes.

The demands on the steel used are cor-respondingly extreme. It must withstand the enormous forces of even the largest di-mensions, in the most diverse environmen-tal conditions. For example telescopic cranes that Liebherr developed for use in Russia have to operate at temperatures down to –50 °C. Conventional steels would rapidly become brittle at these tempera-tures.

Material concepts for exceptional performanceBuderus Edelstahl has developed reliable material concepts for Liebherr to satisfy the most exacting demands.

The special engineering alloys from Wetz lar travel to many regions of the world with the Liebherr cranes on major building sites. They are there when new wind power generators are erected, ports constructed, pipelines laid and bridges built.

Liebherr cranes were also used to build new arenas for the 2010 Football World Cup in South Africa, such as the Green Point Stadium in Cape Town, where one of the two FIFA 2010 World Cup semi-finals is to be played. With 68,000 seats, the 52 metre high arena is one of South Afri-ca’s finest stadiums. Built by specialists like Liebherr. World-class technology for more product benefit is the principle in Ehingen. With world-class materials from Buderus Edelstahl.


He had just been hanging up the little chain, says Wolfram Thom as he joined his colleagues Rudolf Lux, Klaus Rubin and Toni Härter. The “little chain” weighs almost 60 kg. It is not the longest or the heaviest chain, just one of hundreds constantly in use in the Buderus Edelstahl production workshops. They send their chains to Wolf-ram Thom to be checked, and receive a re-placement from the chain forge, so that

operations can continue uninterrupted. All maintenance and repair is recorded metic-ulously in the computerised chain data-base. In a few moments, Rudolf Lux can tell you what parts of a chain have been re-paired or replaced. That is quite a feat, con-sidering that many of the chains move around with their enormous loads between locations within the production workshops. Yesterday they may still have been hanging

on the chain stand, today they are in use, and tomorrow they may be ready for sling-ing on a crane. The chain database has 130 items for the annealing plant alone. Rudolf Lux comments “We give every chain a spe-cial link with an identifi cation number in one of its connectors, so that they can all be allocated to the particular person res-ponsible. They have numbers punched on them with data on the diameter, use and chain number.”

Tables are displayed throughout the production workshops providing infor-mation on the permissible safe working load for the chains in use. Of course only branded products are used. The smallest of these chains has a chain-link material dia-meter of 6 mm, the largest 50 mm. Chains up to a diameter of 36 mm are made up on a modular basis in the chain forge from prefabricated parts; those with larger dia-meters are supplied ready-made. The cost of this runs into six-fi gure sums a year, be-cause abrasion, fracture and elongation by

A chain is only as strong as its weakest link, as Goethe observed in his novel “Wilhelm Meister’s Journeyman Years”. There are four knowledgeable veterans in the Buderus Edelstahl chain forge who ensure the integrity of the whole chain, the chain of people and product. But the daily round of Rudolf Lux and his colleagues is not devoted entirely to strong chains; they also deal with the ingot moulds, and numerous other tasks.

Employees

Between chains and ingot moulds

The Buderus Edelstahl chain forge

The chain forge team: Wolfram Thom, Klaus Rubin, Toni Härter, Rudolf Lux (from left to right)


from the concrete left over”, laughs Klaus Rubin, adding, “Basically we do all sorts of things in between.”

The team incidentally also keeps coming up with ideas to improve production pro-cesses and make cost savings. “When it comes to developing solutions such as new jigs”, explains Toni Härter, “we get inten-sively involved. We develop the right tools and resources for trials with various steels that are to be melted together to find the best structures.”

Tomorrow we’re going to the top platformWith all these tasks, virtually every day is different. “Only in the morning”, says Klaus Rubin, “the routine is always the same. The slag scrapers for removing the slag from the steel have to be cleaned, and the samp-ling ladle too. The temperature lances are due for repair, and it may be time to change parts on the electric arc furnace oxygen blowing manipulator.”

Klaus Rubin is in charge of Buderus Edelstahl’s reusable casting moulds, techni-cally known as ingot moulds. He is respon-sible for ingot mould inspection and in-coming inspection, he coordinates their receipt and delivery, checks and manages stocks of ingot moulds, and decides which ingot moulds can be re-used, and which are to be scrapped. His tasks also include re-pairing the oxygen and burning equipment, and maintaining the temperature measur-ing equipment.

But as already mentioned, in principle everyone can and does do everything in the chain forge. Team spirit is a major factor here. Team spirit and resourcefulness. And one clear motto, “Whatever it is, we’ll get it done.”

use are the enemies of every chain. “If chains of this size break”, says Rudolf Lux, “it is enormously dangerous. So regular vi-sual inspection, dimensional accuracy of the hooks, and checking the freedom of movement of the closing links are very im-portant.” Chains that can no longer be re-paired are taken out of service. They often perform one last service, as Klaus Rubin ex-plains. “When we get bulky scrap destined for the furnace, we burn holes in it and pass the old chains through, so we can drag the scrap into the furnace, and melt it to-gether with the chain.”

Everyone can do everythingThe four members of the chain forge team are welded together in the best sense. Ru-dolf Lux, Head of the chain forge, has been with Buderus Edelstahl for 26 years, and trained as a machine fitter in the company training workshop. Klaus Rubin trained as a high-voltage electrician and Wolfram Thom is a qualified heating engineer; they have both been with the company for 25 years, first in production, then in the chain forge. Toni Härter joined them four years ago, and says, “Here I found the place where I can put my professional skills to good use.” He uses his skills as a blacksmith mainly to produce tools and jigs needed in the work-shops.

But in principle, explains Rudolf Lux, eve ryone can do everything here. And that’s a lot – the department’s work in-volves checking the ingot moulds for sur-face damage, including stock admission and issuing, checking and repairing oxygen measuring equipment for steel production, tool forging work, construction metalwork, the most diverse repair work, and last but not least checking chains including stock

management. Each of the four team mem-bers has additional qualifications – special-ising in lifting gear, oxygen lance equip-ment, official issuing of TÜV badges for bolt drivers, to name only the most impor-tant. Wolfram Thom also drives the crane sometimes, when needs must, and a slag pot has to be concreted. “We then quickly make a few stones for the manipulator

Employees

Wolfram Thom assembling a double strand hook-ended chain sling

Rudolf Lux and Klaus Rubin checking a chain in the works

Comparative size of large and small hooks

Toni Härter makes tools and jigs needed in the workshop

News

Buderus Edelstahl’s admission to the Hesse Environment Alliance testifi es to its special services to environment protection, espe-cially with its environment management system to DIN EN ISO 14001 introduced in 2002. The Alliance for Sustainable Regional Development Policy, a collaborative initia-tive by the Hesse state government and Hesse industry and commerce, was formed in the year 2000, and has since been im-plemented as an ongoing task in all the

state government departments respon-sible.

The Hesse Environment Alliance cele-brated its 10th anniversary in June 2001. More than 1,000 members had so far devel-oped and implemented joint projects, and were a link between environment manage-ment, industry and commerce, and local authorities, said the Hesse Prime Minister Roland Koch in connection with the forth-coming anniversary. The Alliance is in-

tended to further strengthen cooperation between industry and commerce, local au-thorities and the state administration. The aims are to strengthen the state by envi-ronmentally sound economic development, to make the location more attractive, and to reduce the bureaucratic burden on com-panies.

100 companies for climate protectionBuderus Edelstahl is also planning to sign the “Climate Protection Charter”. As part of the sustainability strategy of the state of Hesse, the sustainability conference has launched several initiatives with the aim of actively involving everyone in the state.

The “100 companies for climate protec-tion” initiative is also intended to help to create long-term prospects for Hesse, and to make life now and in the future eco-logically sound, socially just, and economi-cally effi cient. Participating companies such as Buderus Edelstahl are signing a Cli-


Environment Minister Silke Lautenschläger offi cially confi rms Buderus Edelstahl’s membership of the Hesse Environment Alliance

On 15 January 2010, Buderus Edelstahl was nominated by the Hesse state government and its contracting partners as a member of the Hesse Environment Alliance. Buderus Edelstahl is also involved in the “100 companies for climate protection” initiative created as part of the sustainability strategy of the state of Hesse.

Committed to climate and environment protection

Buderus Edelstahl:Member of the Hesse Environment Alliance


News/Employees

Editorial information

Publisher: Buderus Edelstahl GmbH

Editor’s address:Buderus Edelstahl GmbHBuderusstraße 25, 35576 Wetzlar Tel. (0 64 41) 3 74-0Fax (0 64 41) 3 74-28 82

Editor:Jens Mohr (responsible for the content)Texts: Alfred Hopf, Anne Kuhlmann,Sigrid Krekel, Jens Mohr

Photo acknowledgements/sources:p. 4-8, 10, 16-17 Daniel Regel;p. 14-15: Liebherr

Overall production:Composition, design and lithography: Die Feder, Konzeption vor dem Druck GmbH, WetzlarPrinting: Druckhaus Bechstein GmbH, Wetzlar

Print run:German 4,000, English 2,000 copies

Printed in Germany 6/2010

© 2010 Buderus Edelstahl GmbH

Long service awards50 years’ serviceCaspari, Rainer 1. 4. 2010

40 years’ serviceBis , Michael 1. 12. 2009Schrödl, Diethelm 1. 1. 2010Heinisch, Gundula 1. 3. 2010

25 years’ serviceDahlbruck, Wilfried 1. 11. 2009Luque Moreno, Alejandro 12. 11. 2009Peuckert, Volker 29. 11. 2009Karamanis, Michael 10. 12. 2009Kundt, Bernhard 2. 1. 2010

Deaths AgeSchmidt, Dieter 6. 10. 2009 69Baron, Erich 31. 10. 2009 82Skamletz, Theodor 31. 10. 2009 76Schürrer, Erich 25. 11. 2009 66Wege, Herbert 4. 1. 2010 78Alt, Walter 14. 1. 2010 78Biermas, Bernd 16. 1. 2010 77

Neul, Andreas 2. 1. 2010Thom, Wolfram 18. 2. 2010Rubin, Klaus 1. 3. 2010Pechanek, Peter 4. 3. 2010Weber, Ernst 18. 3. 2010Hermann, Udo 1. 4. 2010Rech, Ralf 1. 4. 2010Lackmann, Harald 22. 4. 2010Schmidt, Armin 22. 4. 2010

10 years’ serviceMohr, Jens 1. 1. 2010Euen, Norbert 1. 1. 2010Herrmann, Martin 1. 4. 2010Daniel, Diana 1. 5. 2010Wendt, Thomas 17. 5. 2010

AgeBöhm, Hans 16. 1. 2010 86Mehlich, Herbert 20. 1. 2010 85Schmidt, Stefan 12. 2. 2010 46Stein, Heinz 16. 3. 2010 87Ließfeld, Erwin 21. 3. 2010 73Michel, Willi 2. 4. 2010 83Hedderich, Karl 4. 4. 2010 90

mate Protection Charter. This binds them to establish an action plan for more climate protection in their company. This may com-prise energy saving measures, or measures to increase energy effi ciency in their com-pany.

The companies are supported in creating their action plans. Highly committed com-panies also receive a special award if they reduce their climate-damaging emissions by 20 % or more in fi ve years.

“It is a matter of course for us”, says Buderus Edelstahl Technical Director Karl-Peter Johann, “to support this sensible ini-tiative. Admission to the Hesse Environ-ment Alliance shows that we already placed great emphasis on sustainability in the past. We will pursue this commitment fur-ther with our involvement in the “100 companies for climate protection” initia-tive.”

Diary dates for 2010

EuroMoldWorld Fair for Moldmaking and Tooling, Design and Application Development 1 to 4 December 2010Trade Fair Centre, Frankfurt am Main, Germany

Husum WindEnergy 2010The Leading Wind Energy Trade Fair21 to 25 September 2010

Buderus Edelstahl GmbH Buderusstraße 25 D-35576 WetzlarTel. +49 (0) 64 41/3 74-0 Fax +49 (0) 64 41/3 74-28 [email protected] Year · Issue 1 · June 2010

BE_Info_1_2010_engl1.pdf

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